Interconnection device and system

ABSTRACT

A connector system including first housing having a first header, the first header including one or more conductive pads that are in electrical communication with a conductor. A second housing that is mateable with the first housing and includes a second header positioned on a mating face. The second header includes one or more conductive pad that are electrically engaged with a conductor and positioned in confronting relation with the one or more conductive pads of the first header. An interposer located between the first header and the second header, with a woven contact that extends continuously through the interposer toward conductive pads on the first and second headers. The interposer is movable between a first position where the woven contact is spaced away from the at least one of the conductive pads, and a second position where woven contact electrically engages one of the conductive pads.

This application is a continuation-in-part of copending patentapplication Ser. No. 10/736,280, filed Dec. 15, 2003, and entitledElectrical Contact, which application claims the benefit of U.S.Provisional Patent Application No. 60/457,076, filed Mar. 24, 2003, U.S.Provisional Patent Application No. 60/457,258, filed Mar. 25, 2003, andU.S. Provisional Patent Application No. 60/462,143, filed Apr. 8, 2003,and is also related to U.S. Provisional Patent Application No.60/586,777, filed on Jul. 9, 2004.

FIELD OF THE INVENTION

The present invention generally relates to the electricalinterconnection devices, and more particularly to electrical connectorsthat are at the interface between a first electronic device and asubstrate, mating electrical connector, or a circuit board within anelectronic system.

BACKGROUND OF THE INVENTION

Electrical connectors are used in many electronic systems. Asminiaturization of the electronic systems becomes more prevalent, thedimensions of the connector itself decrease but the number of signalcircuits routed through the connector increases. This results in anincreasing number of signals in the limited space of the connector. Asthe signal circuits are spaced closer and the transmission speed of thesignals increases, electromagnetic interference (EMI) and crosstalkbecome a serious problem. It is desirable that the components of aninterconnection path be optimized for signal transmissioncharacteristics; otherwise, the integrity of the system will be impairedor degraded. Such characteristics include low inductance, increasedcurrent carrying capacity, suitable roll-off, and reduced ground bounce.Continuous efforts have been made to develop electrical connectors thathave as little effect as possible on electronic system performance andintegrity.

Inductance is one concern in designing a connector, particularly whenthat connector is to be used in a signal transmission portion of a highspeed electronic system. An example of one such connector is a so called“board-to-board” connector. A board-to-board connector provides theelectrical, and often mechanical interface between printed circuitboards (PCB's) in an electronic system. Such connectors often have anelongated housing defining an elongated array of receptacles or slotsfor receiving a mating edge of the printed circuit board, or a field ofpins projecting from the surface of the PCB that are mated to acorresponding field of contact receptacles. In many applications, suchconnectors are mounted on two or more PCB's commonly referred to as“daughter boards”, which are mounted to a “mother board.”

An inductive effect results from the interconnection of the PCB's whichacts to change the characteristic impedance of the circuit and therebynegatively affect the signal transmission capacity of the system.Accordingly, it is desirable to reduce the inductive effects due to theinterconnection of the PCB's, and thereby fulfill a need for aninterconnection system that reduces inductive effects between the boardsbeing connected. It would also be desirable to increase the currentcarrying capacity between the PCB's. Examples of such prior artboard-to-board connectors may be found in U.S. Pat. Nos. 6,790,048;6,776,668; 6,733,305; 6,729,890; 6,609,914; 6,599,138; 6,464,515;6,338,630; 6,312,263; 6,183,315; 6,089,883; 6,220,903; 6,059,610;6,036,504; 5,921,787; 5,876,219; and 5,873,742, which patents are herebyincorporated herein by reference.

Electrical connectors are often used in environments where they areexposed to dust and dirt, and may even be used in environments wherethey are subject to splash or immersion in water. It is desirable toseal the connector assembly to protect the terminals from exposure tothe external environment. Very often the connector bodies are eachformed with a plurality of passages that extend into the connectorbodies from a cable end, and into which the cables and their terminalsare received. In a sealed connector application, a seal is providedabout the cable such that, when installed in the corresponding passage,it serves to seal the passage from the outside environment. Theconnectors are also sometimes filled with a potting material which willcover the rear entry of the electrical connector so as to protect itfrom the ingress of contaminants. It is necessary to prevent the entryof contaminants into the interior of the electrical connector, sincethese contaminants corrode the electrical contact surfaces which oftenleads to intermittent or unreliable electrical connections. Many typesof seals and sealed connector systems are known for keeping contaminantsfrom entering an electrical connector housing. Examples of such priorart sealed connector systems may be found in U.S. Pat. Nos. 6,821,145;6,767,250; 6,547,584; 6,383,003; 6,132,251; 6,109,945; 6,050,839;5,823,824; 5,785,544; 5,775,944; 5,595,504; 5,356,304; 4,983,344;4,961,713; 4,944,688; 4,934,959; 4,895,529; 4,832,615; 4,776,813;4,772,231; 4,085,993; 4,150,866; and 4,639,061, which patents are herebyincorporated herein by reference.

All of the foregoing connector systems rely upon one or more resilientconductive contacts having a variety of shapes, sizes, and springcharacteristics. A commonly used form of resilient conductive contactincludes an interconnection end for matting with a corresponding end ofa mating contact or PCB, and a termination end for terminating a circuittrace or wire. These ends are often connected by a resilient portion ofthe contact which provides for the storage of elastic energy. Prior artresilient conductive contacts may be a single metal structure in theform of a spring to provide the required elastic response during servicewhile also serving as a conductive element for electrical connection.Typically, a combination of barrier metal and noble metal platings areapplied to the surface of the spring for corrosion prevention and forelectrical contact enhancement. It is often the case that these platingsare not of sufficient thickness for electrical conduction along only thesurface of the spring. Examples of such prior art resilient conductivecontacts may be found in U.S. Pat. Nos. 5,653,598; 5,173,055; 5,059,143;4,906,194; 4,927,369; 4,699,593; and 4,354,729, which patents are herebyincorporated herein by reference.

One problem in the art exists in that a good material for theconstruction of a spring, such as a high strength steel, is not a verygood electrical conductor. On the other hand, a good electricalconductor, such as a copper alloy or precious metal, often does notprovide adequate spring properties. There has been a need in theconnector arts for a more resilient conductive contact whichincorporates the seemingly opposing requirements of good springproperties, temperature resistance, and high conductivity. Therefore, animproved electrical contact for use in an electrical connector is neededwhich can overcome the drawbacks of conventional electrical contacts. Itis desirable that a good electrical contact element possess thefollowing attributes: (a) usable in a wide variety of inter-connectionstructures; (b) a large elastic compliance range and low contact forces;(c) capable of transmitting high frequency signals and high currents;(d) capable of withstanding high operating temperatures; and (e)exhibiting high durability, i.e. >500K repeated deflections.

The prior art has been devoid of at least one of the foregoingattributes necessary for a universally applicable electrical connector.

SUMMARY OF THE INVENTION

The present invention provides a connector system including a firsthousing having a first header positioned on a mating face. The firstheader includes at least one conductive pad that is electrically engagedwith a conductor such as a wire. A second housing is provided that ismateable with the first housing, and includes a second header positionedon a mating face. The second header includes at least one conductive padthat is electrically engaged with a conductor, such as a wire, and ispositioned in confronting relation with the at least one conductive padof the first header. A contact interposer is located between the firstheader and the second header. The contact interposer includes at leastone contact that extends continuously through the contact interposer soas to have a portion projecting outwardly toward the at least oneconductive pad of the first header and another portion projectingoutwardly toward the at least one conductive pad of the second header.The contact interposer is movable between (i) a first position in whichthe portions of the at least one contact are spaced away from theconductive pads, and (ii) a second position in which the portions of theat least one contact electrically engage both of the conductive pads.

The at least one contact is often formed from a precursor material, suchas an etched or stamped metal sheet, or a plurality of interlaced metalwires. The precursor materials may be formed into a tube or otherappropriate shape, and annealed to set their structural form. Theannealed structure may then be cut into short segments to form aplurality of individual electrical contacts. The precursor materials areoften formed by photo-etching a sheet of conductive material into a meshwith openings of predetermined size and shape. The mesh may also be madeby stamping with a conventional metal working die. Alternatively, theprecursor material may be made by manipulating a plurality of wires soas to interlace the wires into a unitary structure in the form of amesh. This embodiment of electrical contact is often formed by weavingor braiding a plurality of wires together to form a mesh, annealing themesh, and cutting the annealed mesh so as to form a plurality ofindividual electrical contacts that each have an extended elastic rangeas a result of the annealing process. The preferred structural formsinclude woven and folded structures of one or more pleats formed fromthe precursor material. Such a folded structure can be made by pressinga unitary mesh structure in a die adapted to form pleated or foldedstructure in the mesh, followed by annealing the pleated or folded meshwhile resident in the die to set permanently the structural form. It isthen cut to form individual electrical contacts. The desired form of theelectrical contact can be made by first rolling a portion of theprecursor material in to a tube and followed by annealing under aconstraint to set the form factor permanently. The tubular structure isthen cut into short segments to form individual electrical contacts.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bemore fully disclosed in, or rendered obvious by, the following detaileddescription of the preferred embodiments of the invention, which are tobe considered together with the accompanying drawings wherein likenumbers refer to like parts and further wherein:

FIG. 1 is a perspective view of a wire-to-wire connector assembly formedin accordance with the present invention;

FIG. 2 is a perspective view of a woven electrical contact of a typeused in connection with one embodiment of the present invention;

FIG. 3 is a perspective view, partially in phantom, illustrating thewinding of individual wires about a central core during the manufactureof the electrical contact shown in FIG. 2;

FIG. 4 is a cross-sectional view of a wire of the type used in formingthe electrical contact shown in FIGS. 2 and 3;

FIG. 5 is a cross-sectional view, similar to FIG. 4, but showing aninsulating layer placed on the outer surface of wire;

FIG. 6 is a top elevational view of an embodiment of wire mesh used toform an alternative electrical contact that may be used with the presentinvention;

FIG. 7 is a magnified view of the mesh shown in FIG. 6;

FIG. 8 is a top view of the mesh shown in FIG. 7, illustrating theprocess of being rolled into a tubular contact;

FIG. 9 is a perspective view of the tubular contact shown in FIG. 8;

FIG. 10 is a top end view of a portion of the mesh shown in FIG. 7,after pleating so as to form yet another embodiment of electricalcontact;

FIG. 11 is a cross-sectional perspective and exploded view of awire-to-wire connector formed in accordance with the present invention;

FIG. 12 is a partially cross-sectional view of a contact interposer andelectrical contacts arranged in accordance with the present invention;

FIG. 13 is a perspective, partially exploded view of an alternativecontact interposer accepting pleaded electrical contacts formed inaccordance with the present invention;

FIG. 14 is a cross-sectional view of the wire-to-wire connector shown inFIG. 11;

FIG. 15 is a cross-sectional view of a fully mated wire-to-wireconnector shown in FIGS. 11 and 14;

FIG. 16 is a perspective view of an alternative embodiment of thepresent invention arranged in a board-to-board connector system;

FIG. 17 is a cross-sectional view of the board-to-board connector systemshown in FIG. 16;

FIG. 18 is a cross-sectional view similar to that shown in FIG. 17, butillustrating a fully mated position;

FIG. 19 is a perspective exploded view of a board-to-board connectorsystem similar to that shown in FIG. 16, but without housings;

FIG. 20 is a cross-sectional view of a board-to-board connector systemshown in FIG. 19;

FIG. 21 is a cross-sectional view similar to that shown in FIG. 20, butillustrating a fully mated position;

FIG. 22 is an exploded perspective view of a wire-to-ribbon cableconnector system formed in accordance with the present invention;

FIG. 23 is a cross-sectional exploded view of the wire-to-ribbon cableconnector system shown in FIG. 19; and

FIG. 24 is a cross-sectional view similar to that shown in FIG. 23, butillustrating a fully mated position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

This description of preferred embodiments is intended to be read inconnection with the accompanying drawings, which are to be consideredpart of the entire written description of this invention. The drawingfigures are not necessarily to scale and certain features of theinvention may be shown exaggerated in scale or in somewhat schematicform in the interest of clarity and conciseness. In the description,relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and“bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing figure underdiscussion. These relative terms are for convenience of description andnormally are not intended to require a particular orientation. Termsincluding “inwardly” versus “outwardly,” “longitudinal” versus “lateral”and the like are to be interpreted relative to one another or relativeto an axis of elongation, or an axis or center of rotation, asappropriate. Terms concerning attachments, coupling and the like, suchas “connected” and “interconnected,” refer to a relationship whereinstructures are secured or attached to one another either directly orindirectly through intervening structures, as well as both movable orrigid attachments or relationships, unless expressly describedotherwise. The term “operatively connected” is such an attachment,coupling or connection that allows the pertinent structures to operateas intended by virtue of that relationship. In the claims,means-plus-function clauses, if used, are intended to cover thestructures described, suggested, or rendered obvious by the writtendescription or drawings for performing the recited function, includingnot only structural equivalents but also equivalent structures.

Referring to FIGS. 1, 16, and 22, a wide variety of electricalinterconnection systems and connectors may be formed in accordance withthe present invention, such as a wire-to-wire connector system 100, aboard-to-board connector system 200, or a wire-to-ribbon connectorsystem 300. In these and other connector systems one or more electricalcontacts 2 are arranged in an interposer assembly 3 including a contactinterposer 5, one or more terminal headers 7, and one or more pilots 9(FIGS. 1-2 and 11-14). Interposer assembly 3 provides for properalignment and orientation of electrical contacts 2 within the particularconnector system where, owing to the resilient structure of electricalcontact 2 which has a significantly increased elastic range and highspeed signal transmission characteristics, the connector system providesenhanced operating characteristics as compared to prior art electricalinterconnection systems.

More particularly, electrical contacts 2 each comprise a large elasticrange as a result of being formed so as to comprise an interlaced orwoven, annealed metal structure that provides a plurality of individualbeam-sections 6 (FIG. 2). Electrical contact 2 may be formed by weavingat least three or four discrete wires 8 together, i.e., manipulating thewires together so as to interlace them to form a unitary structure, tothereby form an electrical contact precursor mesh 12 in either a tubularconfiguration (FIGS. 2-3) or a sheet (FIGS. 6-8).

Advantageously, the tubular embodiments of the present invention arefree standing, requiring no central or longitudinal interiorly locatedsupport structure around which the wires are wound or, an outer or innersupport structure within which the wires reside in a formed electricalcontact configuration, since the combination of interlacing andannealing wires 8 removes the need for any additional integral orover-layed, co-extruded, or over-molded structural support. In otherwords, electrical contacts 2 can be operated for their intended purposewhile simply comprising a mesh that has been manipulated to take a shapesuitable for interconnecting two or more adjacent structures. It is inthis sense then that electrical contacts 2 of the present invention aresaid to comprise an unsupported structure.

In one woven embodiment, three to eight stainless steel wires 8 arewoven together to form a tubular electrical contact 2. In thisarrangement, each wire 8 takes a helical path so as to be interlacedwith each adjacent wire 8, while at the same time, each wire 8 onlyundergoes a substantially elastic deformation, i.e., each wire 8 wouldexhibit bending properties wholly consistent with the elastic limitportion of its underlying material's characteristic “stress-strain” or“force-deflection” curve. Substantially no plastic deformation is causedto occur in wires 8 during this manufacturing step. Also, it should beunderstood that at the points of intersection/overlap 9 of wires 8 inmesh 12, no bonding or other mechanical interconnection exists betweenthe adjacent portions of wires 8. As a result of this structuralarrangement, the adjacent portions of each wire 8 that define each ofthe intersection/overlap points 9 are movable relative to one another.It has been found, in braided or interlaced structures, that mechanicalstability may be achieved when the ratio of the diameter of the contactand the lay length is smaller than about two-thirds, when cut into shortsegments even after annealing, where the lay length is the length perwire turn. Thus electrical contacts 2 having a diameter less than aboutfive mils may be manufactured with adequate results.

Significantly, once woven tubular electrical contact 2 is annealed so asto stress relieve wires 8, particularly at the plurality ofintersection/overlap points 9. Metals, such as stainless steel andcopper, comprise a generally cubic crystal structure. It is theparticular variation of this crystalline structure (face-centered-cubic)that gives these metals their ductility allowing for elastic bending ofwires 8 into curved shapes, e.g., by winding or braiding about aremovable mandrel 20 (FIG. 3) However in the present invention, wires 8suffer no such defect dislocation or plastic deformation during weaving.Instead, annealing elastically deformed wires 8 in mesh 12 substantiallyeliminates the elastic strain stored within the wires so that slippageof the metal crystals occurs in a controlled manner. In this way, themetal is composed of regular crystals that have taken a set in theirwoven configuration by relieving the elastic strain induced in each wireby the interlacing or weaving process. Thus, instead of wires 8springing apart when cut into individual electrical contacts 2, theytend to maintain their combined structural integrity, and remain woventogether.

In the present invention, the forming of electrical contacts 2 involvesonly essentially elastic deformation in rolling, braiding, and otherprocesses. Under elastic deformation the formed structure cannot bemaintained without a supporting constraint. Otherwise the structure willfall apart as a result of elastic rebound. Advantageously, electricalcontacts 2 may be formed by constraining them in a precursor form, thenannealing them at a sufficiently high temperature which together withthe stored elastic stress, allows dislocations to be generated and movedso as to permanently set the shape of the electrical contact thusrelaxing the stored elastic strain. The extent of deformation in theelastic range is limited so that the shape of the wire cross-section,for example, will not be altered and it will be easier to design the dieor other means of constraint.

Referring to FIGS. 6, 7, and 10, a folded or pleated structure may beformed by annealing the structure while still elastically deformed in aproperly designed die or other fixture which serves as the constraint.For a rolled electrical contact structure, a properly designedconstraint to maintain the tubular form is necessary during annealing(FIGS. 8 and 9). In one embodiment, mesh 12 is wrapped upon itself so asto form a plurality of overlapping layers providing a substantiallyhelical structure to the tube. In the case of a braided tubularstructure, before cutting, the structure itself acts as a constraintduring annealing.

The annealing of mesh 12 relieves the elastic strain that is inherent inwires 8 as a result of the weaving process, particularly atintersection/overlap points 9 where wires 8 are elastically deformed soas to bend or curve. Absent this annealing step and structure, wires 8and mesh 12 would simply spring apart in the absence of any additionalinternal or external support structure affixed to mesh 12, e.g., apolymeric or elastomeric support core or shell. The combination ofweaving individual wires 8 into a structure having inherentmacro-elastic properties, with an annealing step to set the individualwires 8 in their woven structural arrangement, provides forsignificantly enlarged force deflection properties. Thus when woven intomesh 12 according to the invention, and then annealed, plurality ofwires 8 provide a resilient electrical contact structure having asignificantly increased elastic range. To maintain a good surfacecondition heat treatment should be carried out in a controlledatmosphere furnace at the appropriate temperature for the particulargrade of stainless steel or, in a less preferred embodiment, alloy ofcopper which may also be oil quenched to achieve maximum hardness.

According to the present invention, electrical contact 2 may befabricated from three, four, or more loosely woven or braided conductivefibers or wires using, e.g., a conventional wire braiding machine (notshown). For example, wire braiding machines have long been used inindustry to braid metallic or composite wire into electrical orelectronic cable as an electromagnetic shield, or into hydraulic hoseand cordage as a load bearing structure. One such braiding machine thatis suitable for forming electrical contact 2 is a maypole type machinewherein carriers for bobbins carrying the individual wires 8 to bewoven, are moved by horn gears or notched rotors on a deck with all ofthe carriers following alternating circular or arcuate paths around abraiding point. In the present invention, the braiding point may bedisposed along a removable cylindrical mandrel 20, or some otherremovable center support (FIG. 3). Half the bobbin carriers travel inone direction around the braiding point (located along removablecylindrical mandrel 20) following one alternating path, while the otherhalf of the carriers travel in the opposite direction around thebraiding point following another alternating path which crosses thefirst path at each alternating direction. As the two sets of carrierstravel in opposite directions around the braiding point, each crossingthe path of the other, the wires leaving the bobbins are interwoven asthey converge to the braiding point. A continuous tube of electricalcontact precursor material is drawn from the conventional wire braidingmachine. The electrical contact precursor is then annealed followed byprocessing through a cutting station where it is cut transversely intoindividual electrical contacts 2. Such machines are well known in theart, e.g., as disclosed in U.S. Pat. Nos. 3,783,736; 5,085,211;5,257,571; and 5,931,077, which are all incorporated herein byreference.

Another type of braiding machine useful for forming electrical contact 2is known as a rotary braiding machine (not shown). In these machines,there is a set of inner carriers, a set of outer carriers and a set ofstrand deflectors located between the inner and outer carriers. Theinner and outer carriers are rotated so as to follow a circular pathabout the braiding point in opposite directions. The deflectors stand inthe pathway of the strands from the outside carriers. These deflectorscause the wires from the outer carrier to cross the path of the innercarrier thus interweaving the wires. The interwoven wires then convergeto the braiding point to form the woven electrical contact 2. Hereagain, a continuous tube of electrical contact precursor material isdrawn from the rotary braiding machine, annealed, and then processedthrough a cutting station where it is cut transversely into individualelectrical contacts 2. Such machines are also well known in the art,e.g., as disclosed in U.S. Pat. No. 4,275,638, which patent isincorporated herein by reference.

Suitable electrically-conductive fibers or wires include virtually anyfiber material having a bulk resistivity below about 100 μΩ-cm, andpreferably about 2 to 5 μΩ-cm. Typically, the electrically-conductivefibers will be conductive metal wires, such as, tungsten and its alloys,stainless steel, or alloys of copper, that may have portions coated withhighly conductive metals (identified by reference numeral 25 in FIG. 2),such as, silver, palladium, rhodium, gold, and the various alloysthereof. These highly conductive metals may extend along a firstinterconnect portion 31 or a second interconnect portion 33 of eachelectrical contact 2 (FIG. 12). Alternatively, suitable electricallyconductive fibers can be prepared by modifying electrically insulatingfibers, such as by introducing a conductivity-imparting agent, e.g.,metal particles, to a natural or synthetic polymer or other material,such as carbon. While polymer composites may not be able to withstandtypical annealing temperature, a ceramic/metal composite may be usedwith good effect.

Typically, electrically-conductive wires suitable for use in the presentinvention will have a diameter in the range from about 0.025 to 0.1millimeters. The spacing between adjacent conductors (identified byreference numeral 26 in FIG. 2) are typically in the range from about0.1 to 0.5 millimeters as measured between opposing wire intersectionpoints 9. Referring to FIGS. 4 and 5, wires 8 may either be bare or havean insulation coating 27 applied to their outer surface. In all cases,the weave should be sufficiently loose, with gaps or intersticesremaining between adjacent wires 8 so that during longitudinally appliedcompression, wires 8 form a plurality of elastically deformablebeam-sections 6 so as to provide a required spring force.Advantageously, electrical contact 2 is subjected to an annealingprocess so as to substantially set each individual wire 8 in its bent orcurved shape and as a structural element or constituent of woven mesh12. Annealing for a stainless steel wire is conducted at temperaturesranging from about 500° C. to about 600° C., with about 550° C. beingpreferred for most applications.

In one alternative embodiment of the invention, wires 8 may be woveninto an initially flat mesh 40 (comprising warp and weft wires) whichthen may be formed so as to create a variety of contact structures(FIGS. 6 and 7). For example, mesh 40 may be rolled upon itself so as toform a rolled contact 42 (FIGS. 8 and 9). Mesh 40 may be wrapped uponitself so as to form a plurality of overlapping layers providing asubstantially helical structure to rolled contact 42. Each rolledcontact 42 may then be cut from mesh 40 and assembled within a connectorsystem, as will hereinafter be disclosed in further detail.Alternatively, mesh 40 may be folded so as to create a plurality ofpleats 45 defined by a plurality of troughs 47 and ridges 49 (FIG. 10).A contact edge 50 is defined along the perimeter of pleats 45. Pleatedelectrical contacts 45 may then be cut from mesh 40. In this way, pleats45 act to support the contact within openings 35 (FIG. 13). Engagingcontact edge 50 of pleated electrical contact 45 deforms pleatedelectrical contact 45 to produce a resultant contact force. Here again,annealing pleated contact 45 or rolled contact 42 under a constraintallows for a set to be created in wires 8. In the case of pleatedelectrical contacts 45, a suitable forming tool, having a pleated punchand die set, may be closed on mesh 40 during the annealing process inorder to maintain the structural arrangement in elastically formed wires8.

Referring to FIGS. 1-2, and 11-20, electrical contacts 2 may beassociated with a wide variety of electrical interconnection systemswith good effect. For example, electrical contacts 2 may be positionedand supported within a wire-to-wire interconnection device 100. Atypical wire-to-wire interconnection device 100 that is suitable for usewith electrical contacts 2 includes a pair of substantially circularmateable dielectric housings 60 and 61 that are each molded from asuitable polymer material. Polymeric materials useful in this inventioninclude any material useful in the electronics industry, including,without limitation, thermoplastics (crystalline or non-crystalline,cross-linked or non-cross-linked), thermosetting resins or blends orcomposites thereof. Illustrative examples of useful thermoplasticpolymers include, without limitation, polyolefins, such as polyethyleneor polypropylene, copolymers (including terpolymers, etc.) of olefinssuch as ethylene and propylene, with each other and with other monomerssuch as vinyl esters, acids or esters of unsaturated organic acids ormixtures thereof, halogenated vinyl or vinylidene polymers such aspolyvinyl chloride, polyvinylidene chloride, polyvinyl fluoride,polyvinylidene fluoride and copolymers of these monomers with each otheror with other unsaturated monomers, polyesters, such aspoly(hexamethylene adipate or sebacate), poly(ethylene terephthalate)and poly(tetramethylene terephthalate), polyamides such as Nylon-6,Nylon-6,6, Nylon-6,10, Versamids, polystyrene, polyacrylonitrile,thermoplastic silicone resins, thermoplastic polyethers, thermoplasticmodified cellulose, polysulphones and the like. Examples of somethermosetting resins useful herein include, without limitation, epoxyresins, such as resins made from epichlorohydrin and bisphenol A orepichlorohydrin and aliphatic polyols, such as glycerol, and which canbe conventionally cured using amine or amide curing agents. Otherexamples include phenolic resins obtained by condensing a phenol with analdehyde, e.g., phenol-formaldehyde resin.

Housing 60 often includes a conductor or wire-receiving passageway 64extending through a base wall 66 and surrounded by an annular wall 67that together define an interior recess 69 into which wire-receivingpassageway 64 opens (FIG. 11). Housing 61 often includes awire-receiving passageway 70 extending through a base wall 72 andsurrounded by an annular wall 74 that together define an interior recess77 into which wire-receiving passageway 70 opens. In the illustratedembodiment, annular wall 67 has an outer diameter that is slightlysmaller than the inner diameter of annular wall 74, and includes threads76 along a portion of its length so that housing 60 may be received incorresponding threads 78 on an inner surface of annular wall 74 ofhousing 61 (FIGS. 1 and 11-15). Thus when housing 60 is mated withhousing 61 and rotated, the pair of housings 60,61 move toward oneanother so as to close the distance between the confronting innersurfaces of base walls 66 and 72 (FIG. 15). It will be understood thatsuch wire-to-wire connector systems may include a wide variety ofalternative structures for securely inserting housing 60 into housing61, e.g., latches, bayonet mounts, interference fits, etc.

A pair of guide-cradles 80,81 are often located within housings 60,61 onthe interior surface of base walls 66,72, respectively. Guide-cradle 80often includes a wire-receiving passageway 84 extending through a matingface and surrounded by an annular wall that together define an interiorrecess into which wire-receiving passageway 84 opens. Guide-cradle 81includes a wire-receiving passageway 91 extending through a mating faceand surrounded by an annular wall that together define an interiorrecess into which wire-receiving passageway 91 opens. Guide-cradles 80,81 provide support and organization for wires 99 entering housings60,61. It will be understood that a wire-crimp contact terminal 101 mayalso be received within passageways 84,91 so as to form an electrical orsignal transmission pathway.

Interposer assembly 3 includes a contact interposer 5, a pair oftermination headers 7, and one or more pilot pins 9. Interposer assembly3 is positioned between housings 60,61 with some portions located withinhousing 60 and other portions located on housing 61 (FIGS. 11 and 14).Contact interposer 5 is often formed from a standard epoxy and fiberglass printed wiring board (PCB) 102 having a plurality of through-bores104 defined through its thickness and arranged in a regular pattern orarray of predetermined shape and center-line spacing (FIG. 12). Ofcourse, contact interposer 5 may comprise other materials, e.g.,ceramics, polymers, and/or composite materials. One or more pilot holes106 are defined through contact interposer 5. Electrical contacts 2 arelodged within through-bores 104 and fixed in place via a force fit, anadhesive material, or solder located within each through-bore 104 suchthat a first engagement portion 31 projects outwardly from a first sidesurface of contact interposer 5 and a second engagement portion 33projects outwardly from a second side surface of contact interposer 5.

Termination header 7 may be formed from a standard epoxy and fiber glassprinted wiring board (PCB) material having a plurality of through-bores112 defined through its thickness and arranged in a regular pattern orarray that is complementary to the pattern of through-bores 104 incontact interposer 5 (FIGS. 11, 14, and 15). One or more pilot holes 114are also defined through portions of termination header 7 in locationsthat will allow for coaxial alignment with pilot holes 106 of contactinterposer 5 when interposer assembly 3 is positioned within housings 60and 61. Of course, termination headers 7 may comprise other materials,e.g., ceramics, polymers, and/or composite materials. Advantageously,through-bores 112 are plated throughout their internal length with aconductive metal, e.g., tin, gold, or the like, and closed off at aninterior end. In this way, a terminal pad 118 is formed on face 117 ofeach terminal header 7 (FIG. 14) so as to hermetically sealthrough-bores 112 from the ambient environment, but provide anelectrically conductive pathway to wires 99 or wire-crimp terminalcontact 101. Terminal pads 118 are arranged on face 117 of each terminalheader 7 in a regular pattern or array that is complementary to thepattern of through-bores 104 in contact interposer 5. An o-ring 119 orequivalent may be fixedly positioned on face 117 of one of terminalheaders 7 so as to be in surrounding relation to the array of terminalpads 118.

Interposer assembly 3 is mounted within a wire-to-wire connector 100 inthe following manner. Guide-cradles 80, 81 are first positioned withinhousing 60, 61, respectively, such that wire-receiving passageways 84 ofguide-cradle 80 are arranged in coaxially aligned relation withwire-receiving passageway 64 of housing 60, and wire-receivingpassageways 91 of guide-cradle 81 are arranged in coaxially alignedrelation with wire-receiving passageway 70 of housing 61. Once in thisposition, a termination header 7 is positioned on each mating face ofeach guide-cradle 80, 81. In this position, terminal pads 118 faceoutwardly. Pilot pins 9 are then fixedly positioned within pilot holes114 of at least one of termination headers 7 (shown within housing 61 inFIGS. 11, 14, and 15). It will be understood that guide-cradles 80,81are mounted within housings 60,61 such that at least one of housings60,61 may rotate freely about its respective guide-cradle. In this way,the positional and electrical correspondence between terminal pads 118on each terminal header 7 will be maintained during mating of housing 60to housing 61. With pilot pins 9 located in pilot holes 114, a contactinterposer 5 may be positioned within the wire-to-wire connector system100. More particularly, a contact interposer 5 having a plurality ofelectrical contacts 2 positioned within through-bores 104 is arranged inconfronting coaxial relation with termination header 7 which has pilotpins 9 positioned within pilot holes 114. Once in this position, contactinterposer 5 is moved toward termination header 7 so that pilot pins 9are received within pilot holes 106. The tips of pilot pins 9 may thenbe swaged or otherwise capped so as to prevent contact interposer 5 fromeasily sliding off pilot pins 9.

Wire conductors 99 or wire-crimp terminal contact 101 are then insertedthrough wire-receiving passageways 64, 70, 84, and 91, respectively, sothat a conductive end portion of each is positioned within aplated-through-hole 112 of each termination header 7 (FIG. 14). In thisposition, each wire 99 or wire-crimp terminal contact 101 is thensoldered in place so as to create an electrical engagement and signaltransmission pathway with the underside of a conductive pad 118 on eachtermination header 7.

With wires 99 or wire-crimp terminal contact 101 electrically engagedwith termination headers 7, within housings 60, 61, housing 60 may bemated to housing 61 so as to complete wire-to-wire connector 100.Referring to the exemplary sequence illustrated in FIGS. 14 and 15,housing 60 is oriented so as to be in confronting coaxial relation withhousing 61 such that threads 76 on the lower outer surface of annularwall 67 engage corresponding threads 78 of annular wall 74 of housing61. Once in this position, one of housings 60, 61 is rotated relative tothe other so as to cause threads 76, 78 to engage one another andthereby pull housings 60, 61 toward one another. As this occurs,conductive pads 118 on termination header 7 of housing 60 move towardengagement portions 31 of each electrical contact 2 that is positionedin contact interposer 5. Conductive pads 118 engage electrical contacts2 and thereby cause contact interposer 5 to slide toward housing 61upon, and guided by pilot pins 9 so as to move engagement portions 33 ofeach electrical contact 2 towards conductive pads 118 of terminationheader 7 positioned within housing 61. Engagement portions 33 of eachelectrical contact 2 thus engage conductive pads 118 of terminationheader 7 in housing 61 so as to complete each electrical circuit.

Of course a wide variety of connector systems may employ interposerassembly 3 so as to operate in accordance with the present invention.For example, a board-to-board connector system 200 may be formed havinga interposer assembly 3 as follows. Referring to FIGS. 16-18, insimplified form a board-to-board connector system 200 may include a pairof mateable housings 202,203 in which interposer assembly 3 may bepositioned. Of course, interposer assembly 3 may be employed forboard-to-board applications without the use of housings 202,203 withadequate results (e.g., board-to-board connector system 201 shown inFIGS. 19-21). In an embodiment that includes housings, each will ofteninclude an annular side wall 206,207 that surrounds a centrally disposedopening 209,210, with an annular ledge 212,214 that is arranged toproject into the opening from the bottom of annular side wall 206,207(FIG. 17). In the illustrated embodiment, annular wall 206 is slightlysmaller than annular wall 207 so that housing 202 may be received withina portion of housing 203. Thus when housing 202 is mated with housing203, the pair of housings move toward one another so as to close thedistance between the confronting inner surfaces of annular ledge 212,214(FIG. 18). It will be understood that such board-to-board connectorsystems may include a wide variety of alternative structures forsecurely inserting and holding housing 202 in engagement with housing203, e.g., latches, an interference fit, a threaded rod, nut and springmounting system 216, etc.

Interposer assembly 3 includes a contact interposer 5, a pair oftermination headers 217, and one or more pilot pins 9, and is positionedbetween housings 202,203 with some portions located on housing 202 andother portions located on housing 203 (FIGS. 17 and 18). Contactinterposer 5 is again formed from a standard epoxy and fiber glassprinted wiring board (PCB) 102 having a plurality of through-bores 104defined through its thickness and arranged in a regular pattern or arrayof predetermined shape and center-line spacing (FIGS. 12 and 17). One ormore pilot holes 106 are defined through contact interposer 5.Electrical contacts 2 are lodged within through-bores 104 and fixed inplace within each through-bore 104 as previously described, such that afirst engagement portion 31 projects outwardly from a first side surfaceof contact interposer 5 and second engagement portion 33 projectsoutwardly from a second side surface of contact interposer 5 (FIG. 12).

Termination headers 217 are also formed from a standard epoxy and fiberglass printed wiring board (PCB) material having a plurality ofconductive vias 220 defined through their thicknesses and arranged in aregular pattern or array that is complementary to the pattern ofthrough-bores 104 in contact interposer 5. One or more pilot holes 114are again defined through portions of each termination header 217 inlocations that will allow for coaxial alignment with pilot holes 106when interposer assembly 3 is positioned on housings 202 and 203. Vias220 may comprise plated-through holes that extend through the thicknessof each termination header 217, and that are plated along their internallength with a conductive metal, e.g., tin, gold, or the like, and closedoff at both ends. Alternatively, vias 220 may be solid or semi-solid,electrically conductive structures, e.g., slugs or posts of copper,carbon, or other electrically conductive materials. In this way, a pairof terminal pads 218,219 are formed on both outer faces 222, 223 of eachterminal header 217 so as to provide an electrically conductive pathwayto corresponding terminal pads 225 located on printed wiring board 228(FIG. 17). An o-ring 119 or equivalent may be fixedly positioned onouter face 223 of one of terminal headers 217 so as to be in surroundingrelation to the array of terminal pads 218, if sealing is required for aparticular application.

Interposer assembly 3 is mounted within a board-to-board connectorsystem 200 in much the same manner as with wire-to-wire connector system100. More particularly, termination headers 217 are positioned such thata peripheral edge surface of each outer face 223 engages a respectiveannular ledge 212,214 of housings 202,203. In this position, terminalpads 218 face outwardly toward the corresponding pads 225 on printedwiring board 228. Pilot pins 9 are then fixedly positioned within pilotholes 114 of at least one of termination headers 217 (shown withinhousing 203 in FIGS. 16, 17, and 18). With pilot pins 9 located in pilotholes 114, a contact interposer 5 may be positioned within the connectorsystem 200. More particularly, a contact interposer 5 having a pluralityof electrical contacts 2 positioned within through-bores 104 is arrangedin confronting coaxial relation with termination header 217 which haspilot pins 9 positioned within pilot holes 114. Once in this position,contact interposer 5 is moved toward termination header 217 so thatpilot pins 9 are received within pilot holes 106. The tips of pilot pins9 may then be swaged or otherwise capped so as to prevent contactinterposer 5 from sliding off pilot pins 9. In another embodiment,housing 202, 203 may be discarded with adequate results (FIGS. 19-21).

Housing 202 may be mated to housing 203 so as to complete board-to-boardconnector system 200 in the following manner. Referring to the exemplarysequence illustrated in FIGS. 17 and 18, housing 202 is oriented so asto be in confronting coaxial relation with housing 203 such thattermination headers 217 are facing one another with contact interposer 5positioned between them. Once in this position, housings 202, 203 aremoved toward one another, e.g., by actuation of nut and spring mountingsystem 216. As this occurs, conductive pads 218 on termination header217 of housing 202 move toward engagement portions 31 of each electricalcontact 2 that is positioned in contact interposer 5. Conductive pads218 engage electrical contacts 2 and thereby cause contact interposer 5to slide toward housing 203 upon, and guided by pilot pins 9 so as tomove engagement portions 33 of each electrical contact 2 towardsconductive pads 218 of termination header 217 positioned within housing203. Engagement portions 33 of each electrical contact 2 thus engageconductive pads 218 of termination header 7 in housing 203 so as tocomplete each electrical circuit.

In another example, a wire-to-ribbon cable connector system 300 may beformed having a interposer assembly 3 as follows. Referring to FIGS.22-24, in simplified form a wire-to-ribbon connector system 300 includesa pair of mateable housings 302,303 in which interposer assembly 3 maybe positioned upon guide-cradles 80, 81 as previously discussedhereinabove. In this embodiment, each housing 302,303 includes a basewall 306,307 that is surrounded by an annular wall 309,310. Base wall310 defines an interior recess 314 within housing 303. In theillustrated embodiment, annular wall 309 is slightly smaller in diameterthan annular wall 310 so that housing 302 may be received within aportion of housing 303. Thus when housing 302 is mated with housing 303,the pair of housings move toward one another so as to close the distancebetween the confronting inner surfaces of base walls 306,307 (FIG.22-24). It will be understood that wire-to-ribbon connector system 300may include a wide variety of alternative structures for securelyinserting and holding housing 302 in engagement with housing 303, e.g.,latches, an interference fit, a threaded rod, bayonet mount, etc.

Interposer assembly 3 includes a contact interposer 315, a terminationheader 317, one or more pilot pins 9, and is positioned between housings302,303 with some portions located on housing 302 and other portionslocated on housing 303. A pair of guide-cradles 80,81 are often locatedwithin housings 302,303 on the interior surface of base walls 306,307,respectively, and as previously described hereinabove. Contactinterposer 315 is formed from a standard epoxy and fiber glass printedwiring board (PCB) 102 having a plurality of through-bores 104 definedthrough its thickness and arranged in a regular pattern or array ofpredetermined shape and center-line spacing (see, FIG. 12) however in awire-to-ribbon embodiment of the invention electrical contacts 2 areoften arranged in a circular pattern. It should be noted that contactinterposer 315 may have a wide variety of physical shapes, as dictatedby a particular connector structure. One or more pilot holes 106 aredefined through contact interposer 315. Electrical contacts 2 are lodgedwithin through-bores 104 and fixed in place within each through-bore 104as previously described, such that a first engagement portion 31projects outwardly from a first side surface of contact interposer 5 andsecond engagement portion 33 projects outwardly from a second sidesurface of contact interposer 5.

Termination headers 317 may be formed from a standard epoxy and fiberglass printed wiring board material having a plurality of interconnect322 arranged through their thicknesses. One or more pilot holes 324 aredefined through portions of termination header 317 in locations thatwill allow for coaxial alignment with pilot holes 106 when interposerassembly 3 is positioned on housings 302 and 303. In this embodiment,interconnect 322 may be plated-through-holes or solid conductivestructures or combination of both, e.g., tin, gold, or the like, andclosed off at both ends. In this way, a pair of terminal pads 318, 319are formed on outer faces 326, 327 of terminal header 317 so as toprovide an electrically conductive pathway to corresponding wires 99 andribbon cable 333 (e.g., via solder) within base walls 306,307,respectively (FIG. 22-24). Terminal pads 318 are arranged on outer face326 of terminal header 317 in a regular pattern or array that iscomplementary to the pattern of through-bores 104 in contact interposer315. An o-ring 119 or equivalent may be fixedly positioned adjacent toouter face 326 of terminal headers 317 so as to be in surroundingrelation to the array of terminal pads 318.

Interposer assembly 3 is mounted within a wire-to-ribbon connectorsystem 300 in much the same manner as with wire-to-wire connector system100 and board-to-board connector system 200. More particularly,termination header 317 is positioned on base wall 306 of housing 302.Pilot pins 9 are then fixedly positioned within pilot holes 324 oftermination header 317 (shown within housing 302 in FIG. 20). With pilotpins 9 located in pilot holes 324, a contact interposer 315 may bepositioned within the connector system. More particularly, a contactinterposer 315 having a plurality of electrical contacts 2 positionedwithin through-bores 104 is arranged in confronting coaxial relationwith housing 303 which has pilot pins 9 positioned within pilot holes324. Once in this position, contact interposer 315 is moved towardhousing 303 so that pilot pins 9 are received within pilot holes 106.The tips of pilot pins 9 may then be swaged or otherwise capped so as toprevent contact interposer 315 from sliding off pilot pins 9.

Housing 302 may be mated to housing 303 so as to complete wire-to-ribbonconnector system 300. Referring to the exemplary sequence illustrated inFIGS. 23 and 24, housing 302 is oriented so as to be in confrontingcoaxial relation with housing 303 such that base walls 306,307 arefacing one another with contact interposer 5 positioned between them.Once in this position, housings 302, 303 are moved toward one another sothat housing 302 engages housing 302. As this occurs, conductive pads318 on termination header 317 of housing 302 move toward engagementportions 31 of each electrical contact 2 that is positioned in contactinterposer 315. Conductive pads 318 engage electrical contacts 2 andthereby cause contact interposer 315 to slide toward housing 303 upon,and guided by pilot pins 9 so as to move engagement portions 33 of eachelectrical contact 2 towards conductive pads 318 positioned withinhousing 303. Engagement portions 33 of each electrical contact 2 thusengage conductive pads 323 in housing 303 so as to complete eachelectrical circuit.

It is to be understood that the present invention is by no means limitedonly to the particular constructions herein disclosed and shown in thedrawings, but also comprises any modifications or equivalents within thescope of the claims.

1. A connector system comprising: a first housing having a first headerpositioned on a mating face, said first header including at least oneconductive pad that is in electrical communication with a conductor; asecond housing that is mateable with said first housing and including asecond header positioned on a mating face, said second header includingat least one conductive pad that is electrically engaged with aconductor and is positioned in confronting relation with said at leastone conductive pad of said first header; and an interposer locatedbetween said first header and said second header, with at least onewoven contact that extends continuously through said interposer so as tohave a first portion projecting outwardly toward said at least oneconductive pad of said first header and a second portion projectingoutwardly toward said at least one conductive pad of said second header,wherein said interposer is movable between (i) a first position whereinsaid first and second portions of said at least one woven contact arespaced away from said at least one conductive pad, and (ii) a secondposition wherein said first and second portions of said at least onewoven contact electrically engage said at least one conductive pad.
 2. Aconnector system according to claim 1 wherein said at least one wovencontact comprises an open-ended substantially cylindrical springcomprising a plurality of conductors having a longitudinal axis, whereinsaid conductors comprise an absence of either elastic or plasticdeformations such that longitudinal deflection of said spring results insubstantially only elastic deformation of said plurality of conductors.3. A connector system according to claim 1 wherein said at least onewoven contact is formed by a process comprising (i) interlacing aplurality of conductors so as to form a continuous cylinder wherein saidinterlaced conductors elastically engage one another so as to besubstantially only elastically deformed, (ii) annealing said continuouscylinder so as to substantially eliminate said elastic engagement ofsaid conductors; and (iii) cutting said continuous cylinder so as toform at least one open-ended cylindrical woven contact.
 4. A connectorsystem according to claim 1 wherein said first and second housingsinclude a conductor receiving passageway extending through a base walland surrounded by an annular wall that together define an interiorrecess into which wire-receiving passageway opens.
 5. A connector systemaccording to claim 1 wherein each of said first and second headersincludes a first face comprising at least one opening leading into atleast one blind hole and a second face on which is located said at leastone conductive pad.
 6. A connector system according to claim 5 whereinsaid at least one blind hole is defined by a surface within said headerincluding a layer of conductive metal and said at least one conductivepad is in electrical communication with said layer of conductive metal.7. A connector system according to claim 1 wherein each of said firstand second headers includes a first face comprising a plurality ofopenings each leading into a blind hole and a second face on which islocated a plurality of conductive pads.
 8. A connector system accordingto claim 7 wherein each of said plurality of blind holes is defined by asurface within said header including a layer of conductive metal, andfurther wherein one of each of said plurality of conductive pads is inelectrical communication with said layer of conductive metal in one ofsaid plurality of blind holes.
 9. A connector system according to claim8 wherein each of said plurality of conductive pads hermetically sealssaid blind bore from the ambient environment, and provides anelectrically conductive pathway.
 10. A connector system according toclaim 1 comprising an o-ring fixedly positioned on a face of one of saidfirst and second headers so as to be in surrounding relation to said atleast one conductive pad.
 11. A connector system according to claim 7comprising an o-ring fixedly positioned on a face of one of said firstand second headers so as to be in surrounding relation to said pluralityof conductive pads.
 12. A connector system according to claim 1 whereinsaid interposer includes at least one through-bore in which said wovencontact is positioned so as to be located between said at least oneconductive pad located on said first and said at least one conductivepad located on second headers.
 13. A connector system according to claim1 comprising at least one pilot pin projecting outwardly from at leastone of said first and second headers.
 14. A connector system accordingto claim 13 wherein said interposer includes at least one pilot holepositioned so that each slidingly receives and guides one of said atleast one pilot pin.
 15. A connector system according to claim 1comprising three pilot pins projecting outwardly from at least one ofsaid first and second headers.
 16. A connector system according to claim15 wherein said interposer includes three pilot holes positioned so thateach slidingly receives and guides one of said three pilot pins.
 17. Aconnector system according to claim 1 wherein said interposer includeswoven contacts that are lodged within through-bores and fixed in placesuch that a first engagement portion of each of said woven contactsprojects outwardly from a first side surface of said interposer and asecond engagement portion of each of said woven contacts projectsoutwardly from a second side surface of said interposer.
 18. A connectorsystem according to claim 1 further comprising a guide-cradle is locatedon an interior surface of at least one of said first and secondhousings, said guide-cradle defining a wire-receiving passagewayextending through a mating face that is surrounded by an annular wallwhich together define an interior recess into which said wire-receivingpassageway opens.
 19. A connector system according to claim 18 whereinsaid guide-cradle provides support and organization for conductorsentering said first and second housing.
 20. A connector system accordingto claim 18 wherein at least one of said first header and said secondheader is positioned within said interior recess of said at least oneguide-cradle, wherein each of said first and second headers includes afirst face comprising a plurality of openings each (i) leading into ablind hole and, (ii) confronting said wire-receiving passageway, and asecond face on which is located a plurality of conductive pads.
 21. Aconnector system according to claim 20 wherein each of said plurality ofblind holes is defined by a surface within said header including a layerof conductive metal, and further wherein one of each of said pluralityof conductive pads is in electrical communication with said layer ofconductive metal in one of said plurality of blind holes.
 22. Aconnector system comprising: a first housing having a first headerincluding a plurality of conductive pads that are electrically engagedwith a conductor; a second housing that is mateable with said firsthousing and having a second header including a plurality of conductivepads that are positioned in confronting relation with said plurality ofconductive pads on said first header; and an interposer located betweensaid first header and said second housing, with a plurality of wovencontacts extending continuously through said interposer so that each ofsaid woven contacts has a first portion projecting outwardly toward acorresponding one of said plurality of conductive pads of said firstheader and a second portion projecting outwardly toward a correspondingone of said plurality of conductive pads of said second housing, whereinsaid interposer is movable between (i) a first position wherein saidfirst and second portions of each of said plurality of woven contacts isspaced away from said corresponding one of said plurality of conductivepads of said first header, and (ii) a second position wherein said firstand second portions of said plurality of woven contacts electricallyengage said plurality of conductive pads of said first header and saidsecond housing.
 23. A connector system comprising: a first headerincluding a plurality of conductive pads that are each electricallyengaged by one of a plurality of conductors; a second header including aplurality of conductive pads that are each electrically engaged by oneof a plurality of conductors, and are each positioned in confrontingrelation with a corresponding one of said plurality of conductive padsof said first header; and an interposer located between said firstheader and said second header, including a plurality of woven contactsthat each extend continuously through said interposer so as to have afirst portion projecting outwardly toward a corresponding one of saidplurality of conductive pads of said first header and a second portionprojecting outwardly toward a corresponding one of said plurality ofconductive pads of said second header, wherein said interposer ismovable between (i) a first position wherein said first portions of saidwoven contacts are spaced away from said conductive pads, and (ii) asecond position wherein each woven contact electrically engages acorresponding one of said plurality of conductive pads of said firstheader and a corresponding one of said plurality of conductive pads ofsaid second header.
 24. A connector system comprising: a first headerincluding at least one conductive pad that is electrically engaged witha conductor; a second header including at least one conductive pad thatis electrically engaged with a conductor and is positioned inconfronting relation with said at least one conductive pad of said firstheader; and an interposer supported between said first header and saidsecond header, and longitudinally guided by pilot pins, with at leastone contact that extends continuously through said interposer so as tohave a first portion projecting outwardly toward said at least oneconductive pad of said first header and a second portion projectingoutwardly toward said at least one conductive pad of said second header,wherein said interposer is movable between (i) a first position whereinsaid first portion of said at least one contact is spaced away from saidat least one conductive pad of said first header, and (ii) a secondposition wherein said portions of said at least one contact electricallyengage said conductive pads.